TURBOCHARGER INSTALLATION


  1. INSTALL TURBOCHARGER SUB-ASSEMBLY


    1. A01CI29

      Install the 7 stud bolts.

    2. A01CI28

      Install a new gasket and the turbocharger with 4 new nuts and 4 spacer.

      Torque:
      70 N*m  { 714 kgf*cm, 52 ft.*lbf }

    3. Connect the connector.

  2. INSTALL INTAKE PIPE


    1. A01CHMZ

      Install a new gasket and the intake pipe with the bolt and 2 nuts.

      Torque:
      Bolt
      18 N*m  { 179 kgf*cm, 13 ft.*lbf }
      Nut
      28 N*m  { 285 kgf*cm, 21 ft.*lbf }
    2. A01CJ2T

      Connect the No. 2 air hose with the band.

  3. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01CH67

      Install 4 new gaskets and No. 2 water by-pass pipe sub-assembly, temporarily tighten the 2 union bolts.

    2. Temporarily tighten the No. 2 water by-pass pipe sub-assembly bracket with the nut.

    3. Tighten the 2 union bolts.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

    4. Tighten the nut.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  4. INSTALL NO. 1 TURBO WATER PIPE SUB-ASSEMBLY


    1. A01CHX1

      Install a new O-ring onto the No. 1 turbo water pipe.

    2. Install 2 new gaskets and the No. 1 turbo water pipe sub-assembly with the union bolt and bolt.

      Torque:
      Union Bolt
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }
      Bolt
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  5. INSTALL TURBO OIL OUTLET PIPE


    1. A01CHVB

      Install 2 new gaskets and the turbo oil outlet pipe with the 4 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  6. INSTALL TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01CGM4

      Install the 4 new gaskets and turbo oil inlet pipe sub-assembly, temporarily tighten the 2 union bolts.

    2. Temporarily tighten the turbo oil inlet pipe sub-assembly bracket with the bolt.

    3. Tighten the 2 union bolts.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

    4. Tighten the bolt.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  7. INSTALL NO. 1 TURBO INSULATOR


    1. A01CHIN

      Install the No. 1 turbo insulator with the 2 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  8. INSTALL INTAKE PIPE OR HOSE STAY


    1. A01CHDEE01

      Install the intake pipe or hose stay with the 2 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  9. INSTALL EGR COOLER SUB-ASSEMBLY


    1. Install the EGR cooler sub-assembly and 2 new gaskets with the 6 bolts.

      Torque:
      69 N*m  { 700 kgf*cm, 51 ft.*lbf }

    2. Connect the 3 water by-pass hoses.

  10. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. A01CI20E01

      Install a new gasket and front exhaust pipe assembly, and temporarily tighten 3 new nuts.

    2. A01CHG1

      Temporarily tighten the bolt.

    3. Tighten the 3 nuts.

      Torque:
      70 N*m  { 714 kgf*cm, 52 ft.*lbf }

    4. Tighten the bolt.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  11. INSTALL EXHAUST RETARDER ASSEMBLY


    1. A01CHNOE01

      Install 2 new gaskets and exhaust retarder assembly with the 4 bolts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
    2. A01CIBFE01

      Connect the vacuum hose.

  12. INSTALL NO. 2 INTAKE PIPE


    1. A01CHOY

      Install the No. 2 intake pipe with the 3 bolts and 2 bands.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  13. INSTALL FRONT MUDGUARD RH

  14. INSTALL ENGINE SIDE COVER RH

  15. ADD ENGINE COOLANT


    1. Add engine coolant.

      Specified capacity
      14.7 liters (15.5 US qts, 12.9 Imp. qts)

      Note

      Never use water as a substitute for engine coolant.

      Tech Tips


      • TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).

      • Contact your TOYOTA dealer for further details.

    2. Check the coolant level inside the radiator by squeezing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add coolant.

    3. Install the radiator cap.

    4. Slowly pour coolant into the radiator reservoir until it reaches the FULL line.

    5. Bleed air from the cooling system.


      1. Warm up the engine until the thermostat opens.

        While the thermostat is open, circulate the coolant for several minutes.

      2. Press the inlet and outlet radiator hoses several times by hand to bleed air.

        Note


        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

    6. Stop the engine and wait until the coolant cools down.

    7. Remove the radiator cap and check the coolant level.

    8. If the coolant level has dropped, add coolant.

    9. Check the coolant level inside the radiator reservoir tank again. If it is below the full level, add coolant.

  16. INSPECT FOR COOLANT LEAK


    1. Remove the radiator cap.

      CAUTION:

      Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    2. A01CIGLE01

      Fill the radiator with coolant and attach a radiator cap tester.

    3. Warm up the engine.

    4. Using a radiator cap tester, increase the pressure inside the radiator to 137 kPa (1.4 kgf/cm2, 19.9 psi), and check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

    5. Install the radiator cap.

  17. INSPECT FOR EXHAUST GAS LEAK